Sewing of industrial textiles with energy absorbing yarns

Abstract

A woven fabric seamed region is provided, comprising a top surface and a bottom surface, wherein the woven fabric is formed in a repeating pattern of warp yarns interwoven with weft yarns, and at least one of the warp yarns or the weft yarns is at least partially formed of a laser energy absorbing material. In the fabric seamed region, to maintain or achieve a desired flexibility and / or shear resistance of the fabric, a yarn formed of a laser energy transparent material can be joined to a yarn formed at least partially of a laser energy absorbing material by laser welding. A method of forming such a fabric seamed region is also provided.

Description

[0001] Cross-reference of related patent applications

[0002] The following reference is incorporated herein by reference as if fully described: U.S. Provisional Patent Application No. 63 / 027,096, filed May 19, 2020. Technical Field

[0003] This invention relates to industrial textiles, including papermaking fabrics, particularly molded fabrics and TAD fabrics, and more specifically to seams in such industrial textiles. Background Technology

[0004] Both molded fabrics and TAD fabrics are typically woven from polymer yarns or monofilaments in plain weave, then join the ends of the woven fabric at a certain length together to form an endless loop. A seam can be formed by unweaving and re-weaving the ends of the yarns forming the fabric, resulting in little or no discontinuity and its characteristics at the seam. This causes the machine-directed (MD) yarns to terminate, typically pointing towards the machine side of the fabric.

[0005] Paper machines operate at high speeds with oscillating tension, resulting in tensile stress on the MD orientation. The seams of the fabric are typically weaker than the bulk fabric, making them more susceptible to stress during machine operation. Under tension, the MD yarn terminations may slip from their original positions enough to protrude from the paper surface, damaging the product being manufactured, or separate from their original positions far enough to cause seam failure and the entire fabric to tear in the transverse direction (CD) of the machine.

[0006] Because MD and CD yarns intersect in the seam area, traditional seam forming methods and TAD fabrics rely on friction to hold the seam together. Recently, in the papermaking fabric industry, it has become known to fuse the yarns together, particularly by using laser welding of thermoplastic materials, to achieve improved seam strength and reduce movement at the seam termination.

[0007] US 8,062,480 discloses a process for producing seams in paper and industrial fabrics, and the seams produced by that process. Laser energy is used to weld or melt certain points in the industrial fabric.

[0008] US 20150096704 discloses a stable woven seam for a plain-woven circular fabric tape, comprising machine-direction (MD) yarns and machine-crossing (CD) yarns. The fabric tape has two ends joined in the seam region by bringing the ends of the MD yarns together in pairs to form a joint. These MD yarns are also woven together with CD yarns in the seam region. A portion of the yarns comprises yarns made of a thermoplastic polymer material transparent to light (i.e., laser) in a specific wavelength range. In the seam region, a joint is formed at the yarn contact points by absorbing laser energy. In the seam region, a plurality of spaced-apart strip-shaped fabric segments are formed in a pattern such that a strip-shaped fabric segment without a joint is formed between two adjacent fabric segments having joints.

[0009] US 20130333792 A1 discloses a stable fabric seam for a plain-woven continuous fabric strip with intersecting yarns. Within the fabric seam area, there are at least two strip-shaped regions extending across the entire width of the fabric seam and containing intersections. These intersections are arranged between strip-shaped regions where there is an intersection between the MD and CD yarns. The intersections are joined by transmission welding.

[0010] US Patent 20070028997 A1 discloses a shaped fabric for a papermaking machine, as well as a method and apparatus for manufacturing the shaped fabric. To increase stability, the cross-yarns are joined together at the intersection, and some of the yarns are fused together. The latter is achieved by the fact that when the first and second yarns cross, the first yarn absorbs laser energy, causing its surface to melt, and subsequently the first and second yarns fuse together.

[0011] US 20200063344 A1 discloses a ring-shaped fabric tape having a seam area including MD lines, CD lines interwoven with the MD lines, and termination areas distributed throughout the seam area. Up to 75% of the CD lines are fusible and are distributed in various patterns throughout the seam area. Multiple termination areas also include at least one fusible CD line attached to the MD lines in the termination area.

[0012] Uniformity of air permeability and fabric-TAD roll contact at the microscale is desirable to ensure uniform heat transfer and drying across the entire paper web. This requires uniform air permeability and flexibility of the fabric in both the machine direction and the transverse direction. Fusion yarns in concentrated areas can cause localized discontinuities in fabric air permeability and flexibility, which can leave marks on the paper due to differences in airflow or heat transfer. Similarly, fusion yarns throughout the seam area or in densely packed sections of the seam can lead to undesirable paper defects and runnability problems due to abrupt changes in fabric shear properties.

[0013] Another important fabric property to maintain is the uniformity of the fabric's shear modulus within its plane. Shear modulus is a measure of a fabric's ability to resist deformation in the XY plane when shear loads are applied.

[0014] It is important to provide fabric in the seam area that retains the fabric's properties, particularly breathability and thickness. This should also provide uniform hardening, especially without concentrated areas of high or low hardness.

[0015] It is desirable to provide a fabric with a seam area that overcomes the problems of the prior art by providing a solution that allows selective bonding between warp and weft yarns throughout the seam, in order to provide the desired flexibility and / or shear resistance of the assembled fabric, and to minimize the difference in strength and uniformity between the fabric body and the seam area. Summary of the Invention

[0016] On one hand, a fabric with a seam area is provided, the seam area comprising warp yarns interwoven with weft yarns in a repeating pattern, a termination area distributed throughout the seam area, wherein all or all weft yarns, but not both, have been formed at least partially by a laser energy absorbing material.

[0017] Fabrics with seam areas can be single-layer or multi-layer woven.

[0018] In one embodiment, a single-layer fabric is provided having all weft yarns formed at least partially of a laser energy absorbing material. Here, preferably, the warp yarns are formed of a laser energy transparent material, and at the point where the warp yarns pass between the applied energy and the weft yarns formed at least partially of the laser energy absorbing material, the warp yarns are connected to the weft yarns formed at least partially of the laser energy absorbing material.

[0019] In another embodiment, the single-layer fabric provided having all warp yarns or all weft yarns formed at least partially of a laser energy absorbing material comprises only all warp yarns formed at least partially of a laser energy absorbing material. Here, preferably, the weft yarns are formed of a laser energy transparent material, and at the point where the weft yarn passes between the applied energy and the warp yarns formed at least partially of the laser energy absorbing material, the weft yarns are connected to the warp yarns formed at least partially of the laser energy absorbing material.

[0020] Preferably, the warp and weft yarns are formed of a thermoplastic material. The thermoplastic material may be polyamide, polyethylene terephthalate, polyurethane, or a mixture thereof, such as a mixture of polyethylene terephthalate and thermoplastic elastomer.

[0021] The yarn, at least partially formed of a laser energy absorbing material, also contains additive materials. A preferred laser energy absorbing material includes carbon black. This is mixed with a thermoplastic material used to form all warp or all weft yarns at least partially formed of the laser energy absorbing material. Other laser energy absorbing materials may include graphite, carbon nanotubes, and metal oxides. Other energy-absorbing additives may also be known. Additives may be added in the range of about 0.1 wt% to about 3 wt% of the weight of the CD yarn. Preferably, additives may be added in the range of about 0.3 wt% to about 1 wt% of the weight of the CD yarn. Other laser energy absorbing materials may also be used.

[0022] The selection and weaving pattern of warp or weft yarns, at least partially formed from laser energy absorbing material, can be used to define multiple seams between intersecting warp and weft yarns, which can affect the flexibility and / or shear resistance of the fabric assembly.

[0023] In a preferred embodiment, the weft yarn is at least partially formed of a laser energy-absorbing material, the warp yarn is transparent to laser energy, and at least a portion of the warp yarn is laser-welded to the weft yarn, which is at least partially formed of the laser energy-absorbing material. Furthermore, the weft yarn, which is at least partially formed of the laser energy-absorbing material, may include carbon in the form of graphite, carbon black, or carbon nanotubes. Preferably, the weft yarn, which is at least partially formed of the laser energy-absorbing material, includes carbon black.

[0024] In another embodiment, a multilayer fabric is provided, wherein at least one fabric seam area surface includes an outer surface layer of at least one yarn type (where all yarns of said yarn type are formed of a laser-transparent material) and an outer surface layer of at least one yarn type in a different direction (where all yarns of said yarn type are at least partially formed of a laser-absorbing material). Laser energy can be applied to the fabric seam area on a support side surface, a machine side surface, or both surfaces. At least one surface of the fabric seam area to which laser energy is applied includes at least one yarn type (where all yarns of said yarn type are formed of a laser-transparent material) and at least one yarn type in a different direction (where all yarns of said yarn type are at least partially formed of a laser-absorbing material). Here, as an example, one surface of the fabric seam area may include first and second different weft systems, each system formed of a different yarn type, wherein all weft yarns in the first weft system are at least partially formed of a laser-absorbing material, while all weft yarns in the second weft system are formed of a laser-energy-transparent material, and all warp yarns are formed of a laser-energy-transparent material. The energy-transparent yarns in one direction and the energy-absorbing yarns in the other direction have sufficiently similar compositions that they will bond together during the welding process. These materials can consist of one material or a mixture of multiple materials.

[0025] On the other hand, a method for manufacturing a fabric having a seam area is also provided, comprising the following steps:

[0026] A fabric woven from warp and weft yarns interlaced in a repeating pattern, wherein all warp yarns or all weft yarns are at least partially formed of a laser energy absorbing material, and for other warp or weft yarns that are not at least partially formed of a laser energy absorbing material, all warp or weft yarns are formed of a laser energy transparent material;

[0027] Assemble the warp ends to the termination area of ​​the entire fabric seam region; and

[0028] Laser energy is applied to at least one surface of the fabric seam area, where a bond is formed between the yarn of the laser energy transparent material and the yarn of the laser energy absorbing material at least partially, where the applied energy passes between the yarn of the laser energy transparent material and the yarn of the laser energy absorbing material.

[0029] Laser energy can be applied to the support side surface or the machine side surface, or both surfaces.

[0030] Other aspects of the invention are discussed below and in the claims.

[0031] Brief description of the attached figures

[0032] The foregoing overview and the following detailed description will be better understood when read in conjunction with the accompanying drawings illustrating preferred embodiments of the invention. In the drawings:

[0033] Figure 1 is a schematic cross-sectional view showing the seam area of ​​a fabric known in the prior art.

[0034] Figure 2 is a schematic cross-sectional view showing the additional fabric seam area of ​​the known prior art.

[0035] FIG. 3 This is a schematic cross-sectional view showing the fabric seam area according to a first embodiment of the present invention.

[0036] FIG. 4 It is a woven pattern that overlaps with the pattern at the joint area of ​​the prior art fabric in Figure 1.

[0037] FIG. 5 It is a woven pattern that overlaps with the pattern at the joint area of ​​the prior art fabric in Figure 2.

[0038] FIG. 6 Is with FIG. 3 The first embodiment of the fabric has a woven pattern pattern of overlapping patterns at the seam area.

[0039] FIG. 7AThis is a schematic cross-sectional view showing the fabric seam area according to a second embodiment of the invention before the various components of the woven fabric are joined.

[0040] FIG. 7B It is similar to FIG. 7A A cross-sectional view of the fabric seam area shows the applied bonding energy to form a bond between the energy-transparent MD warp yarns where the energy-transparent MD warp yarns pass through the applied energy and the CD weft yarns, which include energy-absorbing material.

[0041] FIG. 7C This is a cross-sectional view of the fabric seam area, which shows that... FIG. 7B The final bond is formed after laser energy is applied.

[0042] FIG. 8 yes FIG. 7C A plan view of the top surface of the fabric assembly, showing the joining position between the CD weft yarn and the MD warp yarn.

[0043] FIG. 9A This is a schematic cross-sectional view of the second embodiment of the fabric seam area according to the invention, prior to the joining of the various components of the woven base fabric.

[0044] FIG. 9B It is similar to FIG. 9A A cross-sectional view of the fabric seam area, showing the applied bonding energy to form a bond between the energy-transparent CD weft yarns where the energy-transparent CD weft yarn passes through the applied energy and between the energy-absorbing MD warp yarns.

[0045] FIG. 9C This is a cross-sectional view of the fabric seam area, which shows that... FIG. 9B The final bond is formed after laser energy is applied.

[0046] FIG. 10 yes FIG. 9C A plan view of the top surface of the fabric seam area, showing the joint between the CD weft yarns and MD warp yarns of the fabric.

[0047] FIG. 11A This is a schematic cross-sectional view showing the fabric seam area according to a multilayer embodiment of the present invention, wherein laser energy is applied only to the machine side surface.

[0048] FIG. 11B It is a schematic cross-sectional view showing the fabric seam area according to a multilayer embodiment of the present invention, wherein laser energy is applied to the support side surface and the machine side surface.

[0049] FIG. 11CThis is a schematic cross-sectional view showing the fabric seam area according to a multilayer embodiment of the present invention, wherein laser energy is applied only to the support side surface.

[0050] FIG. 12A This is a schematic cross-sectional view showing the fabric seam area according to a second multilayer embodiment of the invention, wherein laser energy is applied only to the machine side surface.

[0051] FIG. 12B This is a schematic cross-sectional view showing the fabric seam area according to a second multilayer embodiment of the present invention, wherein laser energy is applied to the support side surface and the machine side surface.

[0052] FIG. 12C This is a schematic cross-sectional view showing the fabric seam area according to a second multilayer embodiment of the present invention, wherein laser energy is applied only to the support side surface.

[0053] FIG. 13A This is a schematic cross-sectional view showing the fabric seam area according to a third multilayer embodiment of the invention, wherein laser energy is applied only to the machine side surface.

[0054] FIG. 13B This is a schematic cross-sectional view showing the fabric seam area according to a third multilayer embodiment of the present invention, wherein laser energy is applied to the support side surface and the machine side surface.

[0055] FIG. 13C This is a schematic cross-sectional view showing the fabric seam area according to a third multilayer embodiment of the present invention, wherein laser energy is applied only to the support side surface. Detailed Implementation

[0056] The following description uses certain terms for convenience only and not as a limitation. The fabric seam area 20 according to the invention is a seam area for weaving industrial textiles, which can have many industrial applications, such as conveyor belts, etc. The terms "support side" and "machine side" refer to the fabric surface used in a preferred application of the reference fabric in a conveying application; however, these terms only refer to the first and second, top and bottom, or upper and lower surfaces of a planar fabric. "Yarn" is used collectively to refer to monofilaments or multifilament fibers. "Warp" and "weft" are used to refer to yarns or monofilaments according to their position in the loom, where, once the fabric is mounted on a machine, the "warp" and "weft" extend vertically in the fabric and can be machine-direction (MD) or machine-crossing (CD) yarns in the fabric, depending on whether the fabric is planar or continuous. In a preferred arrangement, the woven fabric seam area 20 is planar woven and sewn at the ends of the warp to form a continuous strip, such that the warp yarns are MD yarns and the weft yarns are CD yarns. Regardless of how the woven fabric seam area 20 is manufactured, the names of warp, weft and / or MD and CD used in the following description are interchangeable.

[0057] like FIG. 3 As shown, a preferred application of the fabric seam region 20 according to the invention provides a support side surface 16 and a machine side surface 18. A preferred application of this fabric seam region is for papermaking fabrics, such as forming fabrics, TAD fabrics, press fabrics, and drying fabrics for paper machines. Other applications may include filter cloths and other industrial applications.

[0058] When the weft system is at least partially formed of a laser energy-absorbing material, it should be understood that the weft yarns formed at least partially of the laser energy-absorbing material may only be provided in the seam area of ​​the fabric, but may also extend further into the fabric body, or even throughout the entire fabric. The size of the seam area will vary, but can generally be defined as the area where the warp ends meet at the termination area. It should be understood that when the warp system is at least partially formed of a laser energy-absorbing material, these warp yarns extend along the entire length of the fabric.

[0059] When describing different embodiments of the fabric, even if there are minor differences in shape, such as yarns with different cross-sections, similar component numbers are used for components that have the same function.

[0060] Referring to Figure 1, a fabric seam region 220 according to known prior art is provided, formed of a woven fabric having CD weft yarns 224 interwoven with MD warp yarns 226. The CD weft yarns 224 and MD warp yarns 226 are formed of a laser-transparent material. A laser-weldable coating is applied to the fabric seam region to create a bond 234 when laser energy 230 is applied. Different bond types will be discussed in further detail below. In this embodiment, laser energy 230 is applied to both the support-side surface 216 and the machine-side surface 218 of the fabric seam region, but it may also be applied to only one surface or the other. In this example of the prior art, there is a highly concentrated bond in the fabric seam region, making it rigid compared to the body, which causes the seam to develop into a ridge or crease under shear conditions. This example also produces different air permeability in the seam compared to the body, resulting in undesirable different drying rates.

[0061] Referring to Figure 2, a fabric seam region 220 according to another known prior art is provided, which is formed of a woven fabric having CD weft yarns 224 interwoven with MD warp yarns 226. A plurality of CD weft yarns 224A are at least partially formed of a laser energy absorbing material, while the remaining CD weft yarns 224B and MD warp yarns 226 are formed of a laser-transparent material. In this embodiment, laser energy 230 is applied to the support side surface 216 and machine side surface 218 of the fabric seam region 220, and a joint 234 is formed where the laser energy 230 passes through the MD warp yarns 226 formed of the laser-transparent material to the CD weft yarns 224A formed of at least partially laser energy absorbing material, while no joint is formed where the laser energy 230 passes through the CD weft yarns 224B and MD warp yarns 226, both formed of laser energy transparent material. In this example of the prior art, the seam is more flexible than the example in Figure 1, but the CD strips formed throughout the seam at both the joint and non-joint locations result in areas of undesirable air permeability differences.

[0062] refer to FIG. 3 The first embodiment of the fabric seam region 20 according to the present invention will be described in more detail. The fabric seam region 20 is formed of a woven fabric having CD weft yarns 24 interwoven with MD warp yarns 26, and arrows indicate that warp yarns 26A and 26B terminate at the ends of machine side surface 18.

[0063] Preferably, the CD weft yarn 24 and MD warp yarn 26 are formed of a thermoplastic material such as polyester, and all weft yarns 24 or all warp yarns 26, and in the case of the first embodiment, all weft yarns 24 are at least partially formed of a laser energy absorbing material. Preferably, in this case, the laser energy absorbing material is carbon black mixed into the molten material used to form the weft yarns 24. However, as described in further detail below, all warp yarns 26, but not all weft yarns 24, may be at least partially formed of a laser energy absorbing material. A joint 34 is formed where the warp yarns formed of the laser-transparent material intersect between the applied laser energy 30 and the weft yarns formed at least partially of the laser-absorbing material. In this embodiment, the laser energy is applied to the support side surface of the fabric seam area. The energy is applied to the entire area, but a joint is formed only where indicated. In this example, the joint is evenly distributed throughout the seam, thereby producing a desirable breathable distribution on the MD and CD of the seam area. It also provides the desired level of joint to reinforce the seam while still providing the desired flexibility.

[0064] FIG. 4 to FIG. 6 As shown in Figures 1 to 12 respectively FIG. 3 The diagram shows a woven pattern where the fabric seam areas 220 and 20 overlap with the pattern (represented by shaded boxes) of join 34. The position where the weft yarn crosses the warp yarn is indicated by an empty square (without an "X"). The position where the warp yarn crosses the weft yarn is indicated by an "X" within a square. The position where join 34 occurs is indicated by shaded squares. A shaded square containing an "X" indicates a join where the warp yarn is above the weft yarn. A shaded square that is otherwise empty indicates a join where the weft yarn is above the warp yarn. A square without shade, whether empty or containing an "X," indicates a low wrap where the join is invalid or there is no join at all.

[0065] FIG. 4 The first prior art fabric seam area 220 shown in Figure 1 is representative of the weft yarn 124 and warp yarn 126 weaving pattern, which has a high proportion of joints, resulting in a stiffer fabric seam area compared to the fabric body.

[0066] FIG. 5 The second prior art fabric seam area 220 shown in Figure 2 is representative of the weave pattern of the weft yarns 124 and warp yarns 126, which has joints arranged in the CD belt, resulting in a more flexible seam but causing an area with undesirable differences in breathability.

[0067] FIG. 6 represent FIG. 3 The fabric seam area of ​​the first embodiment of the present invention shown has uniformly distributed joints throughout the fabric seam area, providing flexibility and uniform airflow.

[0068] Referring to FIG7, a second embodiment of the fabric seam region 20' according to the present invention will be described in more detail. The fabric seam region 20' is formed of a woven fabric having CD weft yarns 24 interwoven with MD warp yarns 26.

[0069] like FIG. 7B As shown, laser energy 30 is applied to the support surface 16 to form, in the woven fabric seam area 20', at the point where the warp yarn 26 (in this embodiment formed of a laser energy transparent material and excluding any laser energy absorbing material) intersects with the weft yarn 24, which is at least partially formed of a laser energy absorbing material, as shown. FIG. 7C The joint shown is 34.

[0070] FIG. 8 show FIG. 7A-7C A plan view of the support surface 16 of the fabric, wherein the ellipse represents the joint 34 formed between the various warp yarns 26 in the woven fabric 20' and the weft yarns 24, which are at least partially formed of laser energy absorbing material.

[0071] This arrangement provides a controlled level of stiffness in the fabric seam area through a laser-welded joint 34 formed between the warp yarns 26 and the weft yarns 24. This stiffness is a function of the weave pattern and the number of points through which the laser energy transparent warp yarns 26 pass, the applied energy, and the weft yarns 24, which are formed at least partially by laser energy-absorbing material.

[0072] refer to FIG. 9A-9C Figures 10 and 10 show a third embodiment of the fabric seam region 20” according to the invention. The fabric seam region 20” is formed in the same manner as the fabric seam region 20’, except that in this case, the MD warp yarn 26, having a rectangular cross-section, is at least partially formed of a laser energy absorbing material, while the weft yarn 24 in the first embodiment of the fabric assembly 20’ has a circular cross-section and is at least partially formed of a laser energy absorbing material. In a manner similar to the first embodiment of the fabric assembly 20’ described above, FIG. 9A Showing the seam area of ​​the woven fabric 20. FIG. 9B The application of laser energy 30 is shown to form a joint between the laser-energy transparent weft yarns 24 and at the intersection of the laser-energy transparent weft yarns 24 with the applied energy and the warp yarns 26 formed at least partially by the laser energy absorbing material, thereby giving the woven fabric 20” some additional strength.

[0073] FIG. 9C The completed fabric assembly 20 is shown, wherein there is a laser weld between the weft yarns 24, where the weft yarns 24 cross between the applied energy and the warp yarns 26 formed by at least part of the laser energy absorbing material. FIG. 10 A plan view of the top surface of fabric 20” is shown, indicating the joint 34 between the weft yarn 24 and the warp yarn 26.

[0074] refer to FIG. 11A-11C 12A-12C and 13A-13C show various multi-layer embodiments of fabric seam areas 120, 120', 120" according to the present invention. FIG. 11A-11C A multi-layered embodiment of fabric seam region 120 is provided, wherein the system of weft yarns 24 on machine side surface 18 is at least partially formed of laser energy absorbing material, while the system of warp yarns 26 on machine side surface 18 and the systems of weft yarns 124 and warp yarns 126 on support side surface 16 are both formed of laser energy transparent material.

[0075] FIG. 11A Laser energy 30 is provided to the machine side surface 18, resulting in a joint 34 between the system of warp yarns 26 and the system of weft yarns 24 at a location where the system of warp yarns 26 passes beneath the system of weft yarns 24, which is formed at least partially by laser energy absorbing material. FIG. 11B Laser energy 30 is provided to both the support side surface 16 and the machine side surface 18, thereby forming a joint 34 between the system of warp yarns 26 and the system of weft yarns 24 at a position where the system of warp yarns 26 passes below the system of weft yarns 24 formed at least partially by laser energy absorbing material, and at a position where the system of warp yarns 26 passes above the system of weft yarns 24. FIG. 11C Laser energy 30 is provided to the support side surface 16, resulting in a joint 34 between the system of warp yarns 26 and the system of weft yarns 24 at a location where the system of warp yarns 26 passes over the system of weft yarns 24, which is at least partially formed of laser energy absorbing material.

[0076] FIG. 11B Representations are also provided for different types of joins 34 occurring at the intersections of a system of weft yarns 24A formed at least partially of a laser energy absorbing material and a system of warp yarns 26 formed of a laser energy transparent material. A full wrap join 34A (represented as an empty box) occurs when the yarns of one system (the system of warp yarns 26 in this particular embodiment) wrap around the yarns of another system (the system of weft yarns 24A in this embodiment) in such a manner that the two yarns are in contact at the top or bottom and on both sides. A moderate wrap join 34B (represented as a box with vertical shading) occurs when only one side of the two yarns is in contact with the top or bottom. In cases where the yarns formed at least partially of the laser energy absorbing material contact the yarns formed of the laser transparent material only on the top or bottom surface of the yarn, it should be understood that low wrapping or no wrapping exists, and therefore at most a viscous join 34C (represented as a box with horizontal and vertical shading), which is not a valid join, or no join occurs at all. Join 34A will be the strongest join because the contact area between the warp and weft yarns is the largest, followed by 34B and 34C, which has the weakest join.

[0077] FIG. 12A-12C A second multi-layer embodiment of the fabric seam region 120' is provided, wherein the machine-side surface 18 includes two systems of weft yarns 24A and 24B. The system of weft yarns 24A is formed of a composition compatible with and joinable to the system of warp yarns 26, the system of weft yarns 24A being woven with the system of warp yarns 26 and at least partially formed of a laser energy-absorbing material, while the system of weft yarns 24B is formed of a laser energy-transparent material and is formed of a composition of a different material from the incompatible warp yarn system to form a join. The materials to be joined must contain materials of similar compatibility for joining. In these embodiments, the warp yarn system 26 on the machine-side surface 18 and the weft yarn system 124 and warp yarn system 126 on the support-side surface are also formed of a laser energy-transparent material. In this particular embodiment, the weft yarn systems 24A and 24B of the machine-side surface 18 are alternately positioned at a 50% ratio. The ratio of these systems may not be 50%, but all similar joinable materials will be at least partially formed of a laser energy-absorbing material.

[0078] FIG. 12A Similar to FIG. 11A Because it provides laser energy 30 to the machine side surface 18, at a location where the system of warp yarns 26 passes beneath the system of weft yarns 24A, which is at least partially formed of laser energy absorbing material, a joint 34 is formed between the system of warp yarns 26 and the system of weft yarns 24A. No joint is formed between any intersections between the systems of warp yarns 26 and weft yarns 24B, because neither of these systems includes yarns at least partially formed of laser energy absorbing material. In a similar manner, FIG. 12B Laser energy 30 is provided to the support side surface 16 and the machine side surface 18, resulting in a joint 34 between the system of warp yarns 26 and the system of weft yarns 24A at a location where the system of warp yarns 26 passes below the system of weft yarns 24A formed at least partially by laser energy absorbing material and above the system of weft yarns 24A. FIG. 12C Laser energy 30 is provided to the support side surface 16 at a position where the system of warp yarns 26 passes over the system of weft yarns 24A, which is at least partially formed of laser energy absorbing material, resulting in a joint 34 between the system of warp yarns 26 and the system of weft yarns 24A.

[0079] FIG. 13A-13C and FIG. 12A-12C The similarity lies in that the machine side surface 18 includes two systems of weft yarns 24A and 24B; however, in FIG. 13A-13C In the system, at least part of the weft yarn 24A formed by laser energy absorbing material occupies two-thirds of the machine side surface 18 weft yarn 24.

[0080] Generally speaking, multilayer fabrics may include warp systems comprising first and second warp systems at least partially formed of laser energy-absorbing material in layers located on each of the top and bottom surfaces of the fabric; or, weft systems comprising first and second weft systems at least partially formed of laser energy-absorbing material in layers located on each of the top and bottom surfaces of the fabric. However, those skilled in the art will understand from this disclosure that laser energy-absorbing material may be provided in the weft systems of each layer, or in the warp systems of each layer, or in a weft system in one surface layer and a warp system in another surface layer, provided that in each layer of the fabric, the warp or weft systems at least partially formed of energy-absorbing material are interwoven with the weft or warp systems formed of laser energy-transparent material. The above embodiments of the fabric assembly are considered exemplary, and the weave pattern of the woven fabric and the selection of warp or weft yarns to be at least partially formed of laser energy-absorbing material can be varied to achieve the desired fabric flexibility and / or shear resistance. This can prevent fabric seam areas from becoming too stiff due to unwanted joining of warp and weft yarns in the woven fabric. Laser energy can be applied to the support side surface or the machine side surface, or both surfaces.

[0081] While these embodiments are described in accordance with laser welding and the applied laser energy, those skilled in the art will recognize that these principles can be used to form a joint using other types of energy applied to the seam area of ​​the fabric, wherein at least the weft or warp yarns are at least partially formed of an energy-absorbing material, and for other warp or weft yarns not at least partially formed of a laser energy-absorbing material, all warp or weft yarns are formed of a laser energy-transparent material, such that when energy is applied, a joint occurs at the energy-transparent material between the energy and the woven substrate fabric portion including the energy-absorbing material.

[0082] Having described the invention in such detail, it should be understood, and will be apparent to those skilled in the art, that many physical changes can be made without altering the inventive concepts and principles embodied therein, only a few of which are demonstrated in the detailed description of the invention. It should also be understood that many embodiments are possible, comprising only a portion of the preferred embodiments, with respect to those portions without altering the inventive concepts and principles embodied therein. Therefore, these embodiments and optional configurations should in all respects be considered exemplary and / or illustrative rather than restrictive, and the scope of the invention is indicated by the appended claims rather than the foregoing description, and all alternative embodiments and modifications thereof falling within the meaning and equivalents of the claims are thus included therein.

Claims

1. A stitched woven fabric, comprising: A warp system, interwoven with a repeating pattern and weft system, is used to define woven fabrics with interconnected endpoints in the seam area. The weft system comprises yarns at least partially formed of laser energy absorbing material. In the seam area of ​​the stitched woven fabric, all the weft yarns in the weft system are at least partially formed of a laser energy absorbing material, and The laser fusion joint is formed only at points between at least some of the warp yarns formed of laser-transparent material and the weft yarns formed of laser energy-absorbing material located in the seam region, at which the warp yarns pass through the applied laser energy applied to the entire seam region and the weft yarns formed of laser energy-absorbing material, so that the laser fusion joint is evenly distributed throughout the seam region, resulting in a uniform air permeability distribution of uniform airflow and a level of reinforcement of the seam region and providing the desired flexibility of the joint.

2. The stitched woven fabric according to claim 1, wherein the warp and weft yarns are formed of a thermoplastic material.

3. The stitched woven fabric of claim 1, wherein the laser fusion bonding is located between the warp yarns, the warp yarns forming part of a top surface at a location where the warp yarns pass over the weft yarns formed at least partially by laser energy absorbing material.

4. The stitched woven fabric of claim 1, wherein the laser fusion bonding is located between the warp yarns, and the warp yarns form part of the bottom surface at a location where the warp yarns pass beneath the weft yarns formed at least partially by the laser energy absorbing material.

5. The stitched woven fabric of claim 1, wherein the laser fusion bonding is located above and below the warp yarns passing through at least a portion of the weft yarns formed of a laser energy absorbing material.

6. The stitched woven fabric of claim 1, wherein the stitched woven fabric comprises a single-layer knit.

7. The stitched woven fabric according to claim 1, wherein the stitched woven fabric comprises a multilayered weave comprising a plurality of fabric layers, and the weft system comprises a first and a second system of weft yarns (24A, 24B), and the first system of weft yarns (24A) comprises all the weft yarns of one of the plurality of fabric layers in the seam region (120), the weft yarns in the first system being at least partially formed of a laser energy absorbing material; and the second system of weft yarns (24B) in different fabric layers in the seam region comprises weft yarns (24B) formed of a laser transparent material.

8. The stitched woven fabric of claim 7, wherein the seam region is entirely composed of a first system of weft yarns (24A) formed at least partially by laser energy absorbing material forming the bottom surface.

9. The stitched woven fabric according to claim 8, wherein the applied laser energy (30) is applied from both surfaces of the woven fabric in the seam region (20) such that the laser fusion joint (34) is formed above and below the weft yarn (24A) in a first system of weft yarns, all of which are at least partially formed of laser energy absorbing material, when the warp yarn (26) passes through them.

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